Installation, Start-Up, and Service Instructions
Installation, Start-Up, and Service Instructions
Installation, Start-Up, and Service Instructions
K = 208/230−1−60
H = 208/230−3−60
M = 460/208/230−3−60
L = 460−3−60
S = 575−3−60 Voltage
A = Standard - Unpainted
B = Painted cabinet (Gray) Painted Cabinet Options
A = Standard
Notes:
• All FAS072-150 units and FHS 072-120 units with a “M” voltage designation are triple voltage; i.e., 208/230/460-3-60.
FAS 180 units are also triple voltage in the “M” configuration unless the High Static motor option is used.
“M” voltage is not available on 2-speed indoor fan motor option.
• Single-phase 072 and 091 units designate standard motor and high static drive.
4’ 7−1/2”
[1409.7]
A
A = 7' 11-1/2” [2426] - 20 Ton
= 8” 9-1/2” [2680] - 25, 30 Ton
EQUALIZER LINE
TXV
UPPER SENSING
SPLIT BULB
SOLENOID
VALVE
EQUALIZER LINE SIGHT
TXV AIRFLOW 15 DIAMS TXV GLASS
UPPER SENSING MIN 10
SPLIT BULB FILTER SOLENOID DIAMS
DRIER VALVE 8 DIAMS
SIGHT MIN
GLASS EQUALIZER
AIRFLOW 15 DIAMS TXV LINE FILTER
TXV
MIN 10 SENSING DRIER
DIAMS LOWER
SPLIT BULB
8 DIAMS
MIN
TXV
AIRFLOW 15 DIAMS
MIN 10
DIAMS
8 DIAMS
MIN INDOOR
COIL
Single Circuit Coil Piping Configuration - FAS/FHS072/091 Dual Circuit Coil Piping Configuration - FAS120-336, FHS120-240
For single compressor condensing units. For single compressor condensing units
LEGEND:
TXV – Thermostatic Expansion Valve
NOTE: Component location arrangemetshown for field installation of
sight glasses, solenoid valves, filter driers, and TXV sensing bulbs.
The TXVs and equilizer lines are factory installed.
LEGEND
TXV — Thermostatic Expansion Valve
NOTE: The 8 o’clock position is shown above.
FIRST ON/LAST OFF = B
VERTICAL INSTALLATION Fig. 11 — TXV Sensing Bulb Location
FIRST ON/LAST OF F = A
HORIZONTAL INSTALLATIO N
Fig. 10 — Typical Evaporator Coil Connections
11/8 Nipple, 5 L
7 Suction Upper 11/8 45° Elbow
11/8 Nipple, 83/4 L
11/8 Long Radius Elbow
11/8 Street Elbow
1 Suction Lower 11/8 Nipple, 75/8 L
11/8 Long Radius Elbow
5/ Street Elbow
8
2 Liquid Lower 5/
8 Nipple, 61/2 L
5 /8 Long Radius Elbow
FAS240 5/
8 Street Elbow
3 Liquid Upper 5 /8 Nipple, 91/2 L
5/ Long Radius Elbow
8
11/8 Nipple, 5 L
7 Suction Upper 11/8 45° Elbow
11/8 Nipple, 83/4 L
11/8 Long Radius Elbow
13/8 Street Elbow
1 Suction Lower 13/8 Nipple, 11 L
13/8 Long Radius Elbow
5/ Street Elbow
8
2 Liquid Lower 5/
8 Nipple, 11/2 L
5 /8 Long Radius Elbow
FAS300 5/
8 Street Elbow
3 Liquid Upper 5 /8 Nipple, 191/2 L
5/ Long Radius Elbow
8
WARNING
Failure to follow this warning could result in personal in-
jury or death.
NOTE: Dimensions in [ ] are in millimeters
Do not use gas piping as an electrical ground.
Unit cabinet must have an uninterrupted, unbroken elec-
Fig. 12 — Condensate Drains trical ground to minimize the possibility of personal injury
if an electrical fault should occur. This ground may con-
sist of electrical wire connected to unit ground lug in con-
trol compartment, or conduit approved for electrical
ground when installed in accordance with NEC (National
Electrical Code); ANSI/NFPA 70, latest edition (in Cana-
da, Canadian Electrical Code CSA [Canadian Standards
Association] C22.1), and local electrical codes.
Install disconnect switch and power wiring in accordance Fig. 15 — Wiring and Service Access (Side Panel
with all applicable local codes. See Fig. 14-16 and the Removed)
unit label diagram. Connect power wiring with 1/4-in. ring
terminal.
The FAS/FHS size 072-180 units that have motors wired for
460-v, 3-ph, 60 Hz operation can be field-converted to 208/
230-v, 3-ph, 60 Hz operation. Rewire the motor according to
the diagram plate on the motor. After reconfiguring the mo-
tor, mark the motor specifying 208-v or 230-v operation re-
placing the 460-v sticker information on the units’ corner
RJ A
post.
105° C 600V
Fan motors are factory-installed on all units. Indoor-fan con-
tactors are located in the fan contactor box behind the side
access panel (see Fig. 15 and 16). Wire the thermostat to
23 22 21
W
the 24-v control circuit terminal block located in the side of
the fan contactor control box, according to Fig. 17 or the unit
label diagram. If the air handler is part of a split system, FAN
complete the wiring from the condensing unit to the thermo- CONTACTOR 13 12 11
Before starting unit, check the following and correct as IMPORTANT! / IMPORTANT
necessary: EQUALIZER LINE
SIGHT GLASS
• Are coil baffle plates tight against coil to prevent air LOWER SOLÉNOÏDE
SPLIT FILTER
• Are all electrical connections correct and tight? AIR FLOW TXV
CIRCULATION
• Is TXV bulb located on suction tube per Fig. 20? D'AIR 15 DIAMS MIN 10 DIAMS
15 x DIA. MIN 10 x DIA. MIN
EQUALIZER LINE
CONDUITE D'ÉQUILIBRAGE
• Is the capillary tube to the bulb free of kinks and not 8 DIAMS MIN
8 x DIA. MIN INDOOR COIL
SERVICE
Inspection and maintenance should be performed at regular
intervals and should include the following:
• Complete cleaning of cabinet, fan wheel, cooling coil,
condensate pan and drain, heating coils, and return-
air grille (if present).
• Inspection of panels and sealing of unit against air
leakage.
• Adjustment of fan motor, belt, bearings, and wheels.
• Cleaning or replacement of filters.
Fig. 22 — Fan Shaft, Bearings, and Fan Wheel
• Testing for cooling/heating system leaks. (Typical)
• Checking of all electrical connections.
Centering Fan Wheel
If fan and fan shaft assembly are not properly centered,
WARNING blades may scrape against the blower side scroll plate or
may create an objectionable whistling noise. It may be nec-
ELECTRICAL SHOCK HAZARD essary to adjust individual fan wheels or move entire fan
shaft. See the following two sections.
Failure to follow this warning could cause personal injury
or death. Fan Shaft Position Adjustment
Before performing service or maintenance operations on Loosen setscrew or locking collar of each fan shaft bearing.
unit, turn off main power switch to unit and install lock(s) Slide shaft into correct position and replace locking collar
and lockout tag(s). Ensure electrical service to rooftop (Fig. 23). To replace locking collar, push collar up against in-
unit agrees with voltage and amperage listed on the unit ner face of bearing. Turn collar in direction of fan rotation un-
rating plate. Unit may have more than one power switch. til tight, and tighten setscrew. Tightening locking collar in di-
rection of fan rotation results in further tightening of collar
Most unit service can be performed by removing one or should setscrew work itself loose.
both of the unit’s side panels. Coil cleaning or removal or in-
sulation cleaning may require removal of a rear, top, or bot-
tom panel, depending on the unit’s orientation. When ser-
vice is completed, replace unit panels.
Panels
Panels are fastened to unit frame with sheet metal screws.
Fan and coil compartment must be sealed tightly after ser-
vice to prevent air from bypassing the cooling coil.
Fan Motor Lubrication
Fan motor supplied with unit is permanently lubricated and
requires no further lubrication.
Fan Shaft Bearings
Bearings on size 072-120 units are sealed, permanently lu-
bricated bearings that require no further lubrication. Size
150-336 units have pillow-block bearings (see Fig. 22) that
must be lubricated with suitable bearing grease approxi- Fig. 23 — Fan Shaft Bearing
mately every 3 months. See Table 19 for suitable lubricants.
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution could cause equipment
damage.
Increasing fan speed produces a greater load on motor.
Do not exceed rated capacity of motor.
FILTER
SLID RETAINER
E
CLIP
Condensate Drains
Keep condensate drains free of dirt and foreign matter.
Return-Air Filters
Refer to Replacing Filters section for filter accessibility and
removal. Replace with clean filters of the sizes listed in
Tables 4-11.
• After draining as much water as possible from coils,
add sufficient antifreeze to prevent residual water in
the coil from freezing.
• Add a sufficient quantity of non-corrosive antifreeze
to the entire system to prevent all water within the
system from freezing. Fig. 27 — Remove Filter Retainer Clip
Coil Removal
Remove unit panels and corner posts as required. Discon-
nect coil connections and remove fastening screws. Re-
move coil through end or side sections of unit.
Cleaning Cooling Coil
Remove return-air filters. Remove any heavy dirt that may
have accumulated on underside of coil. Coil can be cleaned
more easily with a stiff brush, vacuum cleaner, or com-
pressed air when coil is dry. If coil is wet or if water is to be
used for cleaning, guard against splashing water on electri-
cal components or damaging surrounding area. Clean coil
baffles as applicable and check for tight fit to be sure air
does not bypass coil.
Cleaning Insulation
The insulation contains an immobilized antimicrobial agent
that helps prevent the growth of bacteria and fungi. Clean
the inner surface of the insulation according to the separate
maintenance instructions shipped with the unit.
Replacing Filters
Filters can be removed and installed from either side of the
unit. Install new filters in units that have one fan as follows:
1. Remove the side access panel (retain screws).
2. Remove the filter retainer clip (see Fig. 27). Fig. 28 — Filter Removal/Replacement
Table 29 — Fan Motor Data, FAS Alternate Motor, Two Speed (SI)
UNIT FAS072 FAS091 FAS120 FAS150 FAS180 FAS240 FAS300 FAS336
208/230-3-60 and 460-3-60
Speed (r/s) 29.17 29.17 29.17 29.17 29.25 29.33 29.25 29.17
Shaft kW 2.76 2.76 2.76 2.76 3.73 5.59 7.46 7.46
Frame (NEMA) 56HY 56HY 56HY 56HY 184T S213T S215T S215T
Shaft Dia (mm) 22.2 22.2 22.2 22.2 28.6 34.9 34.9 34.9
575-3-60
Speed (r/s) 28.50 28.50 28.50 29.25 29.25 29.17 29.25 29.17
Shaft kW 2.76 2.76 2.76 3.73 3.73 5.59 7.46 7.46
Frame (NEMA) 56HY 56HY 56HY 184T 184T S213T S215T S215T
Shaft Dia (mm) 22.2 22.2 22.2 28.6 28.6 34.9 34.9 34.9
Table 31 — Fan Motor Data, FHS Alternate Motor, Two Speed (English)
UNIT FAS072 FAS091 FAS120 FAS180 FAS240
208/230-3-60 and 460-3-60
Speed (rpm) 1750 1750 1725 1755 1760
Hp 3.7 3.7 3.7* 5.0 7.5
Frame (NEMA) 56HY 56HY 56HY 184T S213T
Shaft Dia (in.) 7/
8
7/
8
7/
8 1 1 /8 13/8
575-3-60
Speed (rpm) 1710 1710 1710 1755 1750
Hp 3.7 3.7 3.7 5.0 7.5
Frame (NEMA) 56HY 56HY 56HY 184T S213T
Shaft Dia (in.) 7/
8
7/
8
7/
8 1 1 /8 13/8
* High Efficiency Motor
Table 34 — Fan Motor Data, FHS Alternate Motor, Two Speed (SI)
UNIT FAS072 FAS091 FAS120 FAS180 FAS240
208/230-3-60 and 460-3-60
Speed (r/s) 29.17 29.17 28.75 29.25 29.33
Shaft kW 2.76 2.76 2.76 3.73 5.59
Frame (NEMA) 56HY 56HY 56HY 184T S213T
Shaft Dia (mm) 22.2 22.2 22.2 28.6 34.9
575-3-60
Speed (r/s) 28.50 28.50 28.50 29.25 29.17
Shaft kW 2.76 2.76 2.76 3.73 5.59
Frame (NEMA) 56HY 56HY 56HY 184T S213T
Shaft Dia (mm) 22.2 22.2 22.2 28.6 34.9
II. PRE-START-UP
OUTDOOR UNIT
Is there any shipping damage? (Y/N) ______________
If so, where:
CONTROLS
Are thermostat(s) and indoor fan control wiring connections made and checked? (Y/N) ______________
Are all wiring terminals (including main power supply) tight? (Y/N) ______________
Have outdoor unit crankcase heaters been energized for 24 hours? (Y/N) ______________
INDOOR UNIT
Has water been placed in drain pan to confirm proper drainage? (Y/N) ______________
Are proper air filters in place? (Y/N) ______________
Have fan and motor pulleys been checked for proper alignment? (Y/N) ______________
Do the fan belts have proper tension? (Y/N) ______________
PIPING
Has foam shipping block been removed from the TXV (Thermostatic Expansion Valve)? (Y/N) ______________
Are liquid line solenoid valves located at the indoor unit (FAS) or outdoor unit
(FHS) coils as required? (Y/N) ______________
Have leak checks been made at compressors, condensers, indoor coils, TXVs (Thermostatic
Expansion Valves) solenoid valves, filter driers, and fusible plugs with a leak detector? (Y/N) ______________
Locate, repair, and report any leaks.
Have all compressor service valves been fully opened (backseated)? (Y/N) ______________
Are the compressor oil sight glasses showing correct levels? (Y/N) ______________
COMP A1 COMP B1
Oil pressure ______________ ____________
Suction pressure ______________ ____________
Suction line temp ______________ ____________
Discharge pressure ______________ ____________
Discharge line temp ______________ ____________
Entering outdoor unit air temp ______________ ____________
Leaving outdoor unit air temp ______________ ____________
Indoor unit entering air db temp ______________ ____________
Indoor unit entering air wb temp ______________ ____________
Indoor unit leaving air db temp ______________ ____________
Indoor unit leaving air wb temp ______________ ____________
Compressor amps (L1/L2/L3) ____/____/_____ ____/____/___
NOTES:
CL-2 Specifications are subject to change without notice. 7-19 508 01 1603 01